In the past three years, quietly but powerfully, a drama has been unfolding—one that will reshape the future of steel production in the United Kingdom. Sitting at the hub of this industrial revolution is the £1.25 billion low-carbon steelmaking development by Tata Steel at Port Talbot, South Wales. Far from just an investment, it marks the start of a new industrial revolution, based not on coal and iron ore, but on renewable energy and UK indigenous scrap.
Installing a State-of-the-Art Electric Arc Furnace (EAF)
At the core of this massive project is the installation of a state-of-the-art electric arc furnace (EAF), a cleaner and more sustainable alternative to traditional blast furnaces. Peter Jones, the program manager leading the initiative, brings a lifetime of steelmaking experience to the project, having worked across Port Talbot’s steelworks since 1991. With planning permissions secured and contracts signed, groundwork is set to begin in summer 2025, heralding a transformative period for the industry.
Scrap Handling: The Journey Begins at the Knuckle Yard
The new process starts at the Knuckle Yard, where raw scrap material will arrive via the UK’s mainline railway network. Scrap metal will be entering at a staggering level of 70,000 tons per week, twice the amount currently witnessed. To meet this demand, Tata Steel is re-engineering its container and rolling stock operations to enable rapid and streamlined unloading and transportation to processing centers.
Pea Fields: Preparing Scrap for the Furnace
Next, the scrap is transported to Pea Fields, a ten-pitch-sized site large enough to handle massive volumes. Here, different types of scrap—from heavy demolition material to lighter, cleaner automotive stampings—will be sorted and prepared. The site includes tight environmental safeguards, with strict controls on runoff, noise management, and planning conditions to protect neighboring communities.
Building the Power Infrastructure for Clean Steel
Powering this shift to cleaner production is another enormous project: a new National Grid link to support the giant electricity demands of the EAF. This includes building a new substation, laying a two-kilometer buried high-voltage cable, and installing transformers capable of handling 275,000 volts—scaled down to 33,000 volts for plant operations. Completion is scheduled for October 2027.
Creating Direct Supply Chains: Filling Boss Lagoon
A portion of Boss Lagoon will be filled in to create a direct path for heavy trucks, cutting down travel distance and improving the efficiency of the supply chain. Nearby land will be developed for cooling systems, utilities, and scrap preparation plants, all supporting the new low-carbon steel production process.
Constructing the Giant Electric Arc Furnace at Port Talbot
At the heart of the transformation is the construction of the electric arc furnace inside the steel plant. This colossal structure will feature a 320-ton tap weight and a 160-ton hot heel, capable of holding up to 480 tons of molten steel. Positioned above floor level, the furnace will pour steel into ladles for further processing in secondary steelmaking stages.
Automated Scrap Conveyor and Advanced Emission Controls
Alongside the EAF, a highly automated scrap conveyor system approximately 300 meters long and 20 meters wide will be installed. Designed to preheat scrap and ensure a continuous supply to the furnace, this system enhances energy efficiency. A state-of-the-art fume treatment plant will monitor and control emissions, ensuring compliance with strict environmental standards.
Enhancing Secondary Steelmaking at Port Talbot
Secondary steelmaking is also undergoing a major upgrade. Two new ladle metallurgy furnaces (LMFs) will refine the chemical composition and temperature of molten steel, allowing Tata Steel to continue producing a wide range of high-quality steel grades. This precision engineering process involves alloy mixing and temperature control before casting.
Reusing Legacy Infrastructure: Blending Old with New
Interestingly, some of the existing infrastructure will be retained rather than scrapped. The CAS-2 unit and RDDG Gasser—key components of the old system—will continue operating, providing flexibility and expanding the range of products the plant can produce.
People at the Heart of Tata Steel’s Green Revolution
Above all, the project is about people. Peter Jones emphasizes that the success of the transformation rests on a team of dedicated staff. Many employees are transitioning from operational roles to project management positions, combining deep industry expertise with new skills in engineering and project delivery. Tata Steel’s green revolution is truly people-led.
Forging a Green Future for British Steel
Although this transition marks the end of traditional blast furnace steelmaking at Port Talbot, it represents an ambitious commitment to a sustainable future. A future where British steel is produced not by burning carbon-rich coal, but by recycling scrap with clean, renewable power. This vision addresses customer needs, environmental imperatives, and national interests.
Sharing the Journey: Community Updates and Engagement
As Tata Steel proceeds with construction, it plans regular updates for the community, allowing everyone to track the progress of this landmark project. Far more than just building a plant, this is about telling a story—a story of resilience, reinvention, and renewal for the UK steel industry.
